MAHLE RTI RRC770 User Manual

OPERATION

&

MAINTENANCE

MANUAL

RRC770

Refrigerant Management Center

RTI Technologies, Inc.

4075 E. Market St.

P.O. Box 3099

York, PA 17402

800-468-2321 (Extension 259)

www.rtitech.com

Manual P/N 035-80437-00

TABLE OF CONTENTS

RRC770

Before Using ........................... 2

Safety Precautions ...................... 3

Filling the Charge Cylinder ............... 5

Recover/Recycle ........................ 6

Oil Drain & Air Purge .................... 8

Deep Vacuum ............................ 9

Hose Evacuation ......................... 10

Charge/High Side ........................ 11

Scheduled Maintenance & Filter Maintenance 13

Problems & Solutions .................... 14

Flow Diagram ........................... Appendix

Schematic Diagram ....................... Appendix

CONGRATULATIONS:

You have purchased one of the finest Recovery, Recycling, and Charging
Machines available! Fill out and return the Warranty Card within 90
days to activate warranty and free lifetime technical support.

RTI Technologies, Inc.

BEFORE USING THE RRC770

Check for any shipping damage. Place a claim with carrier if damage is
discovered.

DO NOT USE A DAMAGED UNIT.
Complete and return the Warranty Card to activate technical support

service and warranty coverage:

Warranty claims can not be honored without this warranty card on file.

The RRC770 should not be operated or serviced by any person who has not
read all the contents of this manual. Failure to read and comply with
these instructions or any one of the limitations noted herein can result in
serious injury and/or property damage.

These general instructions describe normal operation and maintenance
situations encountered with the RRC770. The instructions should not be
interpreted to anticipate every possible contingency.

It is the responsibility of the owner/user to operate the RRC770 in
accordance with all specifications and laws which may apply.

The following pages contain rules for safe operation of the RRC770. Taking
precedence over any specified rule listed herein, however, is the most
important rule of all:

"USE COMMON SENSE"

A few minutes spent reading these instructions can make an operator aware
of dangerous practices to avoid and precautions to take for his own safety
and the safety of others.

A regular schedule of inspection of the RRC770 should be established and
records maintained with special attention given to Hoses, Compressor Oil
Level, Moisture Indicator, and Filters.

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SAFETY PRECAUTIONS

! Recover, Recycle, and Charge only the refrigerant for which the

machine is configured.

! Wear safety glasses and protective gloves. Refrigerant has a very low

boiling point and can cause frostbite.

! Follow the RRC770 operating procedures sequentially to avoid

prematurely disconnecting hoses or opening valves which may release
refrigerant to the atmosphere.

! Do not expose the RRC770 to moisture or operate in wet areas.
! Use the RRC770 in locations with mechanical ventilation that provides

at least four air changes per hour.

! Hoses used with the RRC770 must have shutoff devices within 12 inches

of the connection point to the system being serviced to minimize the
introduction of Non-condensable Gas (Air) into the RRC770 and the
release of refrigerant when being disconnected.

! Disconnect power before performing any maintenance or service on the

RRC770.

! Avoid using an extension cord with the RRC770. If necessary, use a good

condition, UL listed, 3-wire grounded, #14 AWG, or larger, extension
cord of the shortest possible length.

! Connect the RRC770 to a properly grounded receptacle. Do not over

load the circuit.

! Do not allow the RRC770 to remain unattended in the Charge Mode with

power On. The Charge Cylinder Heater will be energized creating a high
pressure condition.

NEVER TURN THE CYLINDER UP-SIDE-DOWN.
DO NOT CONNECT THE RRC770 TO THE LIQUID SIDE OF

ANY A/C SYSTEM WITH A CAPACITY GREATER THAN 4 LBS.
REFRIGERANT IN A/C SYSTEMS HAVING LARGER CAPACITIES

MUST BE RECOVERED FROM THE VAPOR SIDE ONLY.
NEVER CONNECT THE RRC770 TO THE LIQUID PORT OF A

CYLINDER OF REFRIGERANT TO FILL THE RRC770 CHARGE

CYLINDER.
FAILURE TO FOLLOW THE ABOVE MAY CAUSE THE RRC770 COMPRESSOR TO

FAIL AND VOID THE WARRANTY.

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L CAUTION 7

Avoid breathing refrigerant or lubricant vapor or mist.

Exposure may irritate eyes, nose and throat.

If accidental system discharge occurs, ventilate work area before
continuing.

Additional health and safety information may be obtained from
refrigerant and lubricant manufacturers.

Special Considerations with R134a

R134a has been shown to be nonflammable at ambient temperature
and atmospheric pressure. However, tests under controlled
conditions have indicated that, at pressures above atmospheric and
with air concentrations greater than 60% by volume, R134a can form
combustible mixtures.

While it is recognized that an ignition source is also required for
combustion to occur, the presence of combustible mixtures is a
potentially dangerous situation and should be avoided.

Under no circumstances should any equipment be pressure tested or
leak tested with Air/R134a mixtures. Do not use compressed air
(shop air) for leak detection in R134a systems.

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FILLING THE CHARGE CYLINDER

A/C Systems requiring service often do not have a full charge of refrigerant.
The RRC770 should be filled until about 3 pounds of liquid refrigerant can be
seen in the Charging Cylinder Sight Glass. The Sight Glass is visible through
a slotted opening on the side of the RRC770.

Figure 1 Filling the Charge Cylinder

To fill the RRC770 Charge Cylinder, refer to Figure 1 and follow these steps:

1. Connect the Red and Blue Hoses to the side of the RRC770, and close the

valves on the end of each hose.

1. Connect the short Yellow Hose provided to the Rear Port of the RRC770
and to the VAPOR port of a cylinder of new or recycled refrigerant. An
adapter is provided with the RRC770 (R134a) which permits the Field
Service Coupler to be attached to the .500 ACME fitting on the cylinder of
refrigerant.

If the cylinder has two ports, observe that the embossed marking on the
cylinder knob says VAPOR or GAS. Do not rely on color coding of the knobs
on the valves.

DO NOT CONNECT TO THE LIQUID VALVE. DO NOT TURN THE CYLINDER UP­SIDE-DOWN. INTRODUCTION OF LIQUID MAY DAMAGE THE COMPRESSOR AND
VOID THE WARRANTY.

2. Press top (ON) of rocker switch marked POWER ON/TEST.

3. Press top (ON) of rocker switch marked RECOVER/RECYCLE.

The green COMPRESSOR RUNNING Light will illuminate and liquid refrigerant
will rise in the Charging Cylinder Sight Glass. When the level is
approximately 3 lbs, close the valve on the refrigerant cylinder. Allow the
RRC770 to continue to run until the Low Pressure Gauge is in a vacuum and the
COMPRESSOR RUNNING Light stays out for at least two minutes. This will
empty the Yellow Hose.

4. Press bottom (OFF) of rocker switch marked RECOVER/RECYCLE.

5. Press bottom (OFF) of rocker switch marked POWER ON/TEST.

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RECOVER/RECYCLE

Figure 2 Recover/Recycle

To Recover/Recycle, refer to Figure 2 and follow these steps:

RTI Technologies, Inc.

1. Attach Red and Blue Hoses to the A/C system per the vehicle manufacturer's
instructions.

Note For R134a Machines

Field Service Couplings on the ends of Service Hoses are of a special design.
The valves have LEFT HAND threads which makes operation opposite to that of

others.

To Close... Turn Counter-clockwise
To Open... Turn Clockwise

The valves MUST BE CLOSED before connecting or disconnecting Field Service
Couplings.

2. Open Red and Blue Hose Valves.

3. Press top (ON) of rocker switch marked POWER ON/TEST.

4. Press top (ON) of rocker switch marked RECOVER/RECYCLE.
The RRC770 will recover and recycle refrigerant from the A/C System, and

then automatically cycle off when a vacuum is sensed. This vacuum level
can be seen on the Low Side Gauge.

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! DO NOT TURN THE RRC770 OFF OR DISCONNECT HOSES !

A small quantity of Liquid refrigerant will probably still remain in the A/C
System. This can be detected by observing an increasing pressure reading
on the Low Side Gauge.

As pressure rises to a preset level, the RRC770 will automatically cycle
on to continue recovering refrigerant. Allow this automatic On/Off
sequence to repeat until the vacuum level remains constant for at least
2 minutes.

... NOTE ...

As refrigerant is processed by the RRC770, temperature variations can
cause vapor to change to liquid which may temporarily settle in
various internal components.

If a known amount of refrigerant has been introduced into the RRC770
it may not all be seen in the Charging Cylinder Sight Glass.

This is normal and nothing to be concerned about. Refrigerant has not
been lost.

The sight glass does not indicate the amount of refrigerant
recovered. It is only accurate for determining the amount of

refrigerant charged out to the vehicle A/C System while in the Charge
Mode of operation.

Note: Press and hold the top of the rocker switch marked PURGE AIR,

which will restart the recovery process to remove any residual
pressure that the RRC770 may not remove when used on cooler
days.

6. Close Red and Blue Hose Valves.

8. Press bottom (OFF) of rocker switch marked RECOVER/RECYCLE.

8. Press bottom (OFF) of rocker switch marked POWER ON/TEST.

INTERNAL CYLINDER FULL LIGHT:
This Light will illuminate if the Charging Cylinder Fills to capacity,

approximately 9 lbs. When this occurs, the Internal Cylinder must be drained
using the charging procedure outlined on Page 11 in order to continue
recovering refrigerant.

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OIL DRAIN & AIR PURGE

Oil and Non-condensable Gas (Air) are
separated from the recovered refrigerant
and MUST be removed following EACH
recycling procedure as follows:

Note: RRC770 must be connected to power
source.

1. Press and hold the Purge Air switch
(below the Contamination Monitor
Gauge) for 5 seconds, and then release
it.

2. Slowly open the Oil Drain Valve (below
cylinder shelf on rear left side of
RRC770) to drain any oil which may have
been removed from the A/C system. A cup
is provided to collect the oil.

Unless the A/C System had previously
been overfilled, the RRC770 will
typically not remove more than a
tablespoon of oil, making replenishment
unnecessary.

LEAVE THE OIL DRAIN VALVE OPEN...

3. Determine the room temperature.

4. Locate the pressure (PSIG) corresponding
to this room temperature ( 0 F) in the
chart on the top of the RRC770. This
chart is reproduced at the right.

If the pressure indicated on the
Contamination Monitor Gauge is greater
than that determined from the chart:

Press and hold the Purge Air Switch
until the Contamination Monitor Gauge
pressure goes down to the pressure
determined from the chart. Any Non­condensable Gas will be vented through
the Oil Drain Valve at this time.

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0F R12 R134a

30 42 40
32 44 42
34 46 44
36 48 46
38 50 49
40 52 51
42 54 54
44 57 56
46 59 59
48 61 61
50 64 64
52 66 67
54 69 70
56 72 72
58 74 76
60 77 78
62 80 82
64 83 85
66 85 88
68 88 92
70 92 95
72 95 97
74 98 104
76 102 107
78 105 110
80 108 114
82 112 118
84 115 123
86 118 127
88 123 130
90 127 135
92 130 140
94 135 145
96 138 148
98 143 153
100 147 157
102 150 163
104 155 167
106 160 173
108 165 180
110 168 185
112 173 190
114 178 195
116 183 200
118 188 207
120 193 213

5. Close the Oil Drain Valve.

6. Press and hold the Purge Air switch for
5 seconds. This permits any residual Non­condensable Gas to be recirculated for
reprocessing during the next recycle
procedure.

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Purge Chart

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DEEP VACUUM

If the A/C System is "opened" for replacing components, a deep vacuum must be
drawn on the system before recharging with refrigerant. This vacuuming
process removes air and moisture introduced into the system. A Vacuum Pump
mounted on the lower rear shelf of the RRC770 provides this capability.

Figure 3 Deep Vacuum

To Deep Vacuum the A/C System, refer to Figure 3 and follow these steps:

1. Connect Red and Blue Hoses to the high and low sides of the A/C System.

2. Open Red and Blue Hose Valves.

3. Press top (ON) of rocker switch marked POWER ON/TEST.

4. Press top (ON) of rocker switch marked DEEP VACUUM.

5. The Vacuum Pump will start and the RRC770 will draw a vacuum.

NOTE... If pressure is sensed at the Red and Blue Hoses on the RRC770, the

Vacuum Pump will not start. If this occurs, perform the
recover/recycle operation described earlier.

6. Press bottom (OFF) of rocker switch marked DEEP VACUUM.

7. Press bottom (OFF) of rocker switch marked POWER ON/TEST.

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HOSE EVACUATION

It's important that Air not be introduced into the A/C System during a Charging
procedure. If a Deep Vacuum procedure was performed previously, the
following Hose Evacuation Procedure is not required. If the service valves on
the hoses have been open, the following procedure must be performed.

Figure 4 Hose Evacuation

To Evacuate Hoses, refer to Figure 4 and follow these steps:

1. Close Red and Blue Hose Valves.

2. Press top (ON) of rocker switch marked POWER ON/TEST.

3. Press top (ON) of rocker switch marked RECOVER/RECYCLE.

4. Let the RRC770 run until the green COMPRESSOR RUNNING light goes out.

Note: If the green light does not illuminate, press and hold the top of

the rocker switch marked PURGE AIR until the COMPRESSOR
RUNNING light turns on.

5. Press bottom (OFF) of rocker switch marked RECOVER/RECYCLE.

6. Press bottom (OFF) of rocker switch marked POWER ON/TEST.

7. Purge any Non-condensable Gas as described in the previous section.

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CHARGE/HIGH SIDE

Figure 5 Charge/High Side

To Charge Refrigerant, refer to Figure 5 and follow these steps:

1. Perform Hose Evacuation described previously.

2. Connect Red and Blue Hoses to the A/C System per the vehicle
manufacturer's instructions.

3. Determine the refrigerant capacity of the A/C system to be charged. This
data is usually printed on a tag located on the accumulator or under the
hood of the vehicle. Convert this quantity to tenths of a pound for setting
the RRC770 charge indicator.

The following will determine where to set the indicator prior to starting
the charge mode:

(RRC770 Liquid Level) - (A/C System Capacity) = Indicator Setting
EXAMPLE: The level of liquid visible in the RRC770 Charging Cylinder Sight

Glass is 7.4 lbs. and the A/C system capacity is 3.2 lbs. The
following calculation results...

(7.4) - (3.2) = 4.2

Therefore, the sliding indicator should be set at 4.2 lbs. in this
example. When the liquid level lowers to the 4.2 lb. mark, a
charge of 3.2 lbs. will have been delivered

NOTE: The Sight Glasses on the Charging Cylinders have markings for

both R12 and R134a. Always use the correct scale for accurate
charging.

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RTI Technologies, Inc.

Note: Skip to step 5 if charging to an optional 30 lb DOT Refillable

Cylinder via the short Yellow Hose attached to the rear port.

4. Open Red and Blue Hose Valves.

5. Press top (ON) of rocker switch marked POWER ON/TEST.

6. Press top (ON) of rocker switch marked CHARGE/HIGH SIDE. Do not start
the Vehicle's Engine. Refrigerant will flow into the high side of the A/C
System. Closely monitor the liquid level as it lowers in the Charging
Cylinder Sight Glass.

7. Press bottom (OFF) of rocker switch marked CHARGE/HIGH SIDE as soon as
the refrigerant level drops to the sliding indicator.

8. Press bottom (OFF) of rocker switch marked POWER ON/TEST.

The vehicle can now be started and the A/C system checked by monitoring Gauge
pressures.

Always close Red and Blue Hose Valves before disconnecting hoses.
Evacuate the hoses per the preceding section "Hose Evacuation".
NOTE: All Refrigerant Recycling Machines charge Liquid, by law. The

preceding is the suggested method of charging liquid into an A/C
system.

Some vehicle manufacturers may not provide a High Side connection.
The above instructions would have to be modified accordingly.
Always follow the vehicle manufacturer’s recommended service
procedures.

EXTERNAL CYLINDER FULL LIGHT:

This Light will illuminate if the External Charging Cylinder Fill to capacity,
approximately 25 (net) lbs, 40 lbs total. When this occurs, the External
Cylinder must be emptied or changed.

Note: The RRC770 will be unable to charge while this light is on, or if

the Yellow Over Fill Protection Cord is NOT connected to the 30
lb DOT Refillable Cylinder.

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SCHEDULED MAINTENANCE

BEFORE EACH USE...Check the oil level in the Compressor and Vacuum Pump

DAILY before using. The Compressor Oil Level Sight Glass is on the left side
of the lower section of the RRC770. The Vacuum Pump Oil Level Sight Glass is
on the end of the pump housing. The oil level should simply be visible in the
glass. If oil is not visible or is above the top of the glasses call Technical
Support at 800-468-2321.

MONTHLY...Clean the Condenser to maintain high efficiency performance of the
RRC770. Disconnect power and remove the lower front perforated panel and
blow compressed air through the cooling fins of the Condenser to remove any
debris. Do not bend the fins on the Condenser coils. Air flow will be
restricted and cause damage to the RRC770. Replace the panel before applying
power to the RRC770.

FILTER MAINTENANCE

Monitor the Moisture Indicator for a color change from BLUE to PINK. When
the RRC770 is new and immediately after changing Combo Filters, the Moisture
Indicators may show PINK. This is due to the exposure to air and does not
indicate inadequate filter performance. Combo Filters are located behind the
front (red) wrap around panel of the RRC770.

The “INLET” Combo Filter (front most of the two) must be changed every 25
hours of operation OR when the Moisture Indicator is Pink. RTI part number
026-80077-00. Hours are indicated on the Filter Change Meter.

The “OUTLET” Combo Filter (rear most of the two) must be changed every 50
hours of operation OR when the Moisture Indicator is Pink. RTI part number
026-80069-00. Hours are indicated on the Filter Change Meter.

1. Remove front (red) wrap around panel to service the Combo Filters.

2. Disconnect Flare Fittings from top and bottom of filters.

3. Remove mounting nuts, and filters.

4. Transfer filter insulation material to new filter as applicable.

5. Install new Combo Filters using hardware removed in Step 3.

6. Connect Flare Fittings to top and bottom of filters.

7. Check for leaks, repair as necessary.

8. Replace front panel.

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PROBLEMS & SOLUTIONS

On rare occasion the RRC770 may seem to be performing incorrectly.
Experience has shown that varying operating conditions can affect the
performance characteristics of the RRC770. The temperature of the vehicle
A/C System will affect how the RRC770 performs.

Following are typical problems with explanations of the possible cause and
solution.

PROBLEM: My RRC770 worked fine all last Summer. I got it out today for

the first service job this Spring and it is very slow in evacuating
the system.

SOLUTION: Today's Spring temperature may be much lower than the average

temperatures during the summer months. Maybe the vehicle was
brought in from outside where the temperature is very low.

The refrigerant in the vehicle will not be under as high a
pressure at lower temperatures and the RRC770 will take longer
to draw a vacuum. More cycles may be required to completely
recover the refrigerant.

PROBLEM: I put 5 lbs. of refrigerant into the RRC770 using the Recycle

Mode. When I checked the sight glass on the Charging Cylinder,
there was less than 5 lbs. I lost Refrigerant. The unit must
leak.

SOLUTION: Due to temperature changes, some refrigerant may condense into

liquid form and stay in tubes and other components in the circuit
preceding the Charging Cylinder. This is normal and will explain
why all refrigerant is not visible in the sight glass.

PROBLEM: I can not get the RRC770 to draw a vacuum as indicated on the Low

Side Gauge.

SOLUTION: Check Hoses for restrictions.
PROBLEM: When I try to fill the Charging Cylinder from an auxiliary

cylinder of clean refrigerant, the RRC770 is really slow or shuts
down.

SOLUTION: The auxiliary cylinder will cool due to the vaporization of

refrigerant. This causes the pressure to decrease.
Use a heat belt to increase the speed of recycling by the RRC770.

14September 28, 1999 Page 14

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PROBLEM: I turned a 30 lb. cylinder of new refrigerant upside down to fill

the Charging Cylinder with liquid. The Charging Cylinder didn't
fill and now the RRC770 won't recover from an A/C system.

SOLUTION: The RRC770 has been overloaded with liquid refrigerant (see

Safety Precaution Section at the beginning of this manual).

... WARNING ...

IF A CYLINDER IS TURNED UP-SIDE-DOWN, THE
RRC770 WILL OVERFILL WITH LIQUID
REFRIGERANT. THIS OVER FILLS THE SUCTION
ACCUMULATOR WITH LIQUID.

FROST ON THE OIL DRAIN ON THE REAR OF THE
RRC770 IS A GOOD INDICATION OF THIS
OCCURRENCE.

THIS SYMPTOM IS CAUSE FOR CONCERN AS LIQUID
REFRIGERANT WILL BE FORCED INTO THE
COMPRESSOR.

THIS CAN DESTROY THE COMPRESSOR AND WILL
VOID THE WARRANTY.

The safest method to remove the
excess liquid which has collected in
the Suction Accumulator is to drain
it from the Oil Drain on the back of
the RRC770 as follows:

Draw a deep vacuum (25 to 29 In. Hg.) on an empty cylinder and
connect it to the Oil Drain Valve. Open the cylinder valve and
the Oil Drain valve.

Close the valves and disconnect the cylinder after the liquid has
been drawn into the cylinder. This refrigerant can now be
recycled by the RRC770 following normal recycling procedures.

If the above suggested solutions do not solve the problem, call 800-468-2321,
ext. 259, and one of our technicians will help diagnose the cause. Please have
the unit available for reference, and be prepared to give us a detailed
description of the fault condition.

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